Polyester yarn and airbags employing certain polyester yarn

ABSTRACT

Airbag cushions manufactured from polyester yarn having certain levels of intrinsic viscosity (IV) and certain specific carboxyl end group (“CEG”) levels perform unexpectedly well in high temperature and high humidity environments for airbag cushion applications. This specification identifies certain polyester yarns and characteristics of such polyester yarns that are necessary to achieve unexpectedly good performance in such high humidity and high temperature applications. A polymeric polyester yarn for airbags, said yarn having a high degree of tenacity even after a long period of exposure to high temperature and high humidity conditions is disclosed. In one aspect of the invention, a polyester yarn having CEG of less than about 60 equivalents/10 6  gram, and more preferably less than about 30 equivalents/10 6  grams, is particularly useful. In another embodiment, a polyester yarn having an IV value of at least about 0.6 performs exhibits superior properties.

Divisional patent application Ser. No. 10/755,121 Filed on Jan. 9, 2004

BACKGROUND OF THE INVENTION

Stabilized nylon 6,6 yarn has been used for some time as a preferredyarn for automotive airbag cushion applications. Relatively highstrength nylon yarns having a tenacity above 8.0 grams/denier arecommonly used in automotive airbag applications.

Nylon 6, 6 yarn when stabilized generally performs well in aging tests.Airbags must pass aging tests to be employed by automotivemanufacturers. Manufacturers provide relatively strict requirements forthe strength performance of airbags after such airbags have enduredsignificant amounts of aging at high temperatures and high humidity.Automobiles are exposed to high temperatures and high humidity for manyyears, and thus airbags within deployment modules installed inautomobiles also must retain their strength so that when and if airbagdeployment occurs, the airbag will be capable of operating properly.

In the past, it has been relatively rare that manufacturers haveemployed polyester yarn for automotive airbag applications. One reasonis that polyester tends to deteriorate over time at high temperature andhigh humidity. Thus, polyester has not been a favorite candidate yarnfor airbags in part because of inadequate performance in humidity agingtests.

It is known that the tenacity of polyester can be increased in someinstances by further drawing the polyester. Tenacity is also known astensile strength. Tenacity is one measure of the strength of polyesteryarn. One drawback to further drawing polyester yarn to achieve highlevels of tenacity relates to the excessive costs associated withdrawing processes in such manufacture.

In the recent past there has been no cost advantage in the use ofpolyester yarn having a tenacity of about 8-9 as compared toconventional stabilized nylon 6,6 yarn which is in widespread use forairbag applications. Conventional polyester yarns available for airbagapplications still sometimes fail to pass the relatively strictautomotive industry requirements for long term strength after such“hydrolytic” aging.

Current industrial applications for polyester usually do not requirethat the polyester yarn withstand relatively high temperatures and highhumidity while still maintaining a relatively high tensile strength fora long period of time. Thus, there is no ready information at hand inthe prior art that identifies what polyester yarn types could besuitable for airbag use.

Polyester chemistry is a highly unpredictable art. The task of findingor formulating a polyester yarn that will perform in airbag applicationsin an extremely difficult task, and often requires a significantexpenditure of research effort and time.

Airbag applications, in contrast to other typical polyester end useapplications, typically require that a yarn maintain at least at about85% of its strength after several thousand hours of exposure torelatively high humidity and high temperature environments. Mostpolyesters that are known in the industry cannot meet such requirements.It would therefore be desirable to discover, identify, characterize, andestablish both physical and chemical characteristics of what productsand processes will provide a polyester yarn that will pass stringenttesting requirements for airbag applications.

In general, the airbag manufacturing industry needs reliable andeffective alternatives to the use of nylon 6,6 for airbag applications.A lower cost alternative to nylon 6,6 would be desirable. Furthermore,the discovery of a manner or a method for manufacturing, measuring,evaluating or applying polyester yarn in a manner that will pass strictautomotive testing requirements would be helpful. The identification andmeasurement of both physical and chemical properties in the polyesteryarn that undesirably lead to deterioration of the yarn would behelpful. Once these properties have been identified and correlated toairbag testing requirements, it may be possible to identify materialsfor airbag applications.

A currently pending, commonly owned and published U.S. patentapplication Ser. No. 10/041,376 and titled “Airbag Made from LowTenacity Yarns” (Milliken file number 5287) published on Jan. 8, 2002.This publication reveals that in certain specific applications airbagsystems may be designed in which a yarn having a tenacity of less thanabout 8.0 grams per denier can be employed in some applications. Thisdisclosure specifically advises placing the seams of the airbag in shearto achieve this effect. Structural modifications are made to the airbagto achieve a satisfactory configuration.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1-3 show hydrolytic aging results for prior art polyester yarns.FIGS. 4-5 show results from work done with one particular polyester yarnthat may be employed in the invention.

FIG. 1 shows the tensile strength changes upon hydrolytic aging at 80°C. and 95% RH of commercially available 650 denier polyester hightenacity yarn currently available from KoSa (designated in FIG. 1 as“PET 1”) and 650 denier polyester high tenacity yarn currently availablefrom Honeywell Corporation (designated in FIG. 1 as “PET 2”);

FIG. 2 is a graph showing the Intrinsic Viscosity (“IV”) changes uponhydrolytic aging (heat and moisture) at 80° C. and 95% RH for the yarntypes mentioned above with reference to FIG. 1;

FIG. 3 reveals the carboxyl end groups (“CEG” or “CEG's”) changes uponhydrolytic aging at 80° C. and 95% RH in micro-equivalents per gram(equivalents/10⁶ gram) at various levels of exposure time for thepolyester yarn types previously identified for FIGS. 1-2;

FIG. 4 illustrates a polyester yarn which may be employed in thepractice of the invention, which provides minimal loss in tensilestrength over time in high temperature and high humidity conditions (80°C. and 95% RH);

FIG. 5 illustrates the hydrolytic aging performance of the polyesteryarn of FIG. 4 of the invention, showing CEG end group levels aftergiven levels of aging exposure at 80° C. and 95% RH; and

FIG. 6 reveals the percentage of broken ester bonds after hours ofexposure at 80° C. and 95% RH, comparing yarns of the prior art (PET 1and PET 2) with one embodiment of the yarns of the invention.

Performance and Technical Characteristics of Currently Available AirbagPolyester Yarns

The performance of known polyester yarns currently commercially offeredfor airbag use in high temperature and high humidity environments (85°C. and 95% relative humidity) have been found to be generallyundesirable after several thousand hours of exposure at 80° C. and 95%RH. In general, polyester performs in a manner that is inferior to nylon6,6 in prolonged exposure environments (i.e. at greater than about 1000hours exposure). Thus, polyester yarns available currently provided inthe industry for use in airbags lose more than about 37% strength whenexposed to 85° C. and 95% relative humidity for about 3000 hours. Thislevel of strength loss is unacceptable for typical airbag applications,and does not meet industry testing requirements.

Turning now to the Figures, inventive work was undertaken to study themechanism of airbag polyester yarn degradation, in an attempt toidentify and characterize what features of polyester can be measuredthat are relevant to the propensity of polyester yarn to degrade.

Commercially available 650 denier polyester from KoSa Company andHoneywell Corporation were evaluated. In the FIGS. 1-3, “PET 1” denotesKoSa brand 650 denier polyester high tenacity yarn. In FIGS. 1-3, “PET2” denotes Honeywell high tenacity polyester yarn, offered commerciallyin the industry for airbags. FIG. 1 shows the aging behavior of twoprior art yarns in the fabric form which were woven in a water-jet loomat a construction of 41×41.

As shown in FIG. 1, the slope of the curve changes rather dramatically(and undesirably) with exposure time. The first portion of the tensilestrength drop for a given amount of exposure time is usually a gradualprocess that becomes more accelerated as exposure time increases. Theaccelerated aging is believed to be catalyzed by the carboxyl endgroups. A large extent of tensile strength loss was observed in theseparticular KoSa and Honeywell polyester yarns. This strength loss ishighly undesirable for airbag applications.

One objective in formulating and identifying polyester yarns of theinvention is to find a polyester yarn type that will not suffer such anundesirable loss in tensile strength following aging. Surprisingly, suchyarn types have been discovered and characterized, as further set forthbelow. Furthermore, it is a goal to identify what physical and chemicalvalues of the many which can be measured will reliably predict polyesteryarn aging behavior and the resultant loss in tensile strength.

Characterization of Polyester by Measuring Intrinsic Viscosity (IV) andCarboxyl End Groups (CEG)

The intrinsic viscosity (molecular weight) changes in FIGS. 2-3, and thepercentage drop for these samples correspond with changes observed intensile strength. The drop in intrinsic viscosity (IV) seems toaccelerate (i.e. become reduced) much faster after a certain time ofexposure. The carboxyl end group (CEG) on the control specimens wasmeasured at 34.3 and 41 equivalents/10⁶ grams for PET1 and PET2respectively. The CEG increased steadily upon exposure and at the end of3000 hrs the concentration rises as high as 79.3 and 104 m.eq/gm forboth polyesters. At this point a considerable loss in the tensilestrength occurs, and airbags manufactured from these yarn types showconsiderable loss in burst pressure. Thus, they are not fit for use. Theincrease in the slope of the tensile strength and IV is believed to bedue in part to auto-catalyzation or further breakdown of ester linkagesin the polyester. Based on this study it is believed that when the CEGconcentration goes beyond about 60 equivalents/10⁶ gm the fabric is nolonger fit for use.

FIG. 3 reveals a CEG value of at least about 80 equivalents/10⁶ gramsfor PET 2, and a CEG value of over 100 for PET1. This may be contrastedwith data generated using a yarn of the invention, as further shown inFIG. 5, for example, as further discussed below.

For the airbag use, the yarn from which the bag is constructed must notlose more than about 10% of the original strength upon aging after 1000hours. Based upon the data in FIG. 1, it is relatively that clear thehydrolytic resistance of this particular polyester at high temperaturesand longer exposure time is detrimental.

DETAILED DESCRIPTION OF THE INVENTION

Surprisingly, it has been found that polyester yarn having certainlevels of intrinsic viscosity (IV) and certain specific carboxyl endgroup (“CEG”) levels perform unexpectedly well in high temperature andhigh humidity environments for airbag applications. Such polyester maybe woven to make an airbag exhibiting superior aging characteristics.Polyester yarns types that never have been employed previously forairbag applications now have been found to be capable of performing insuch applications, if chosen specifically for chemical properties thatare found to be important to aging. This specification identifiescertain polyester yarns and characteristics of such polyester yarns thatare necessary to achieve relatively unexpectedly good performance insuch high humidity and high temperature applications. Properties thatare important include both CEG values and IV values.

It has been found in the practice of the invention that undesirable lossof polyester strength occurs when the polymer backbone of the polyesterchain undergoes a scission mechanism where by the chain length of thepolymer is reduced considerably. This is highly undesirable.

Based upon an understanding of the chemical structure of polyester, asshown below:[—OC—<O>—COOCH₂CH₂O—]_(n)it has been discovered that there is a direct link between the structureof the polyester backbone and the reduction in polyester strengthfollowing high temperature or high humidity conditions. This is asignificant discovery, and the discovery of this fact has led to thecharacterization of polyester types that will perform well for airbags,and is a subject of this invention.

The weakest link in the backbone of the polyester molecule is the esterlinkage (O═C—O). Hence, the ester linkage is believed to be the onlyportion of the polyester molecule that is susceptible to attack in ahigh humidity and high temperature environment. Thus, control polyesteryarn which has a reduced level of CEG is highly desirable, and theseyarn types are the most useful in the practice of the invention.

Further, changes in the backbone of the polyester polymer may bemonitored and evaluated. The intrinsic viscosity (“IV”) changes of theyarn or polymer may be measured to obtain an indication of the molecularweight that should decrease as the chain length is reduced. Furthermore,the CEG separation may be measured to obtain an indication of the degreeof undesirable backbone scission (breakage) which has occurred. Theextent of the increase in this CEG is a significant issue in theperformance of a polyester.

Polyester Yarns Having Certain IV and CEG Levels Have Been FoundDesirable for Airbags

In the invention, it has been found that evaluating IV and CEG ofpolyester yarns is very important in determining which yarns willperform adequately in hydrolytic aging, and which yarns will not soperform. Further, the values of IV and CEG which are found to benecessary for airbag applications have been observed, as reportedherein. Such chemical characteristics typically have not been specifiedor identified for airbag use before this invention. That is, in general,only physical characteristics (like yarn tenacities, elongation,shrinkage, etc.,) have been relied upon for the yarn specificationsprior to the invention of this application. Furthermore, the addition ofchemical inhibitors and end-group capping agents have been found toimprove resistance to aging, in the practice of the invention.

A new airbag has been invented, which may be realized in severaldifferent embodiments, described herein. The airbag may be comprised inpart of woven polymeric polyester yarn, said polyester yarn exhibitingsuperior hydrolytic resistance, said yarn being capable ofcharacterization by a carboxyl end group (CEG) value, wherein said yarnprovides a CEG value of less than about 30 equivalents/10⁶ grams aftersaid yarn is exposed for at least about 336 hours to a temperature of atleast about 85 degrees Centigrade and a relative humidity of at leastabout 95 percent. The time period of 336 hours is the time periodspecified in ASTM D5427, further described herein.

Furthermore, an airbag has been invented in which the airbag iscomprised in part of polyester yarn exhibiting a CEG value of less thanabout 60 equivalents/10⁶ grams after said yarn is exposed for at leastabout 3000 hours to a temperature of at least about 85 degreesCentigrade and a relative humidity of at least about 95 percent,according to ASTM D5427 as modified; and said yarn further provides anIV value of at least about 0.6.

In another aspect of the invention, an airbag is comprised at least inpart of woven polymeric polyester yarn, said polyester yarn exhibitingsuperior hydrolytic resistance, said yarn being capable of beingcharacterized by a carboxyl end group value (CEG), said yarn furtherbeing capable of being characterized by an intrinsic viscosity (IV)value, wherein said yarn provides, after said yarn is exposed for atleast about 3000 hours to a temperature of at least about 85 degreesCentigrade and a relative humidity of at least about 95 percent, thefollowing:

-   -   (a) an IV value of at least about 0.6; and    -   (b) a CEG value of less than about 60 equivalents/10⁶ grams, and    -   (c) a tensile strength of at least about 400 lbs.

An airbag, in the practice of the invention, also may be comprised inpart of woven polymeric polyester yarn, said polyester yarn exhibitingsuperior hydrolytic resistance. The yarn may be capable of beingcharacterized by a carboxyl end group (CEG) value, wherein said yarnprovides a CEG value of less than about 30 equivalents/10⁶ grams aftersaid yarn is exposed for at least about 336 hours to a temperature of atleast about 85 degrees Centigrade and a relative humidity of at leastabout 95 percent. In some applications, the airbag cushion may furtherinclude at least one fabric blank including polyester yarn, saidpolyester yarn exhibiting a CEG value of less than 30 equivalents/10⁶grams and IV value greater than 0.6. An airbag cushion also may beemployed in yet another embodiment of the invention, which has a tensilestrength of the fabric which is greater than about 275 lbs, or greaterthan about 400 lbs. after exposure.

In yet another embodiment, the invention may provide for a woven airbagincluding polyester yarn exhibiting a CEG value of less than about 30equivalents/10⁶ grams and an IV value which is greater than about 0.6.

In one aspect of the invention, an airbag may provide a CEG value ofless than about 50 equivalents/10⁶ grams after exposure to at leastabout 3000 hours at a temperature of at least about 85 degreesCentigrade and a relative humidity of at least about 95 percent. In yetanother embodiment, an airbag having a CEG value of less than about 40equivalents/10⁶ grams after exposure to at least about 3000 hours attemperature of at least about 85 degrees Centigrade and a relativehumidity of at least about 95 percent has been discovered.

In yet another embodiment of the invention, an airbag may be comprisedof polyester yarn retaining at least about 85% of the tensile strengthof said yarn after said yarn is exposed for at least 1000 hours at atemperature of at least about 85 degrees Centigrade and a relativehumidity of at least about 95 percent. An airbag of the invention alsomay be comprised of polyester yarn retaining at least about 85% of thetensile strength of said yarn after said yarn is exposed to at least3000 hours at temperature of at least about 85 degrees Centigrade and arelative humidity of at least about 95 percent.

Furthermore, it has been found that the use during polyester manufactureof chemical stabilizers and end-group capping agents may beadvantageous. That is, in the practice of the invention, agingresistance may be improved through the use of chemical stabilizers. Twoexamples of such stabilizers that can be used are carbodiimide andketene imines. These chemicals are incorporated in the polymerizationstep before the polymer is spun by the yarn manufacturer.

Commercial identifiers for various yarns are provided below. PET 1 & 2as used herein in this specification refer to polyester yarn types whichare currently being offered for airbag use, and thus comprise prior artpolyester yarns, as previously discussed in connection with FIGS. 1-3.

“MD-21” is the term given to only one particular source of polyesteryarn that can be used in the practice of the invention. The yarn “MD-21”as provided herein comprises a polyester yarn Type 560 manufactured byHyosung Corporation of Korea, which has not, until now, been suggestedor discovered for automotive airbag applications.

On the publicly available website of Hyosung, MD-21 yarn type issuggested by Hyosung for truck covers, tents, awnings and the like. Thisis consistent with the general industry opinion that such polyester hasin the past been believed to be unsuitable for uses that requireperformance for long time periods at high temperature and/or highhumidity conditions. Publicly available information would suggest orteach against using such yarn for airbags. Further, chemicalcharacteristics like CEG and I.V. usually are not readily available, andhave not been discovered or published, for airbag yarns, to theknowledge of the inventors. These properties have not, until theinvention of this application, been recognized as being effective forcharacterization of polyester yarn for airbags.

Some of the potential yarns with low CEG's that are available in theindustry for Geotextile applications have been identified from Kosa, butthe elongation on these specimens are very found to be insufficient forto be used in a energy absorbing device like an airbag. However, otherindustrial yarns like Kosa type 784, 786 & 787 can be used for airbagsprovided the CEG values are in the desirable range per this invention.Currently such yarns are used for industrial applications like roofing,awnings, etc. Thus, a surprising discovery of this invention is thatthese and many other polyester yarns are available and may be applied inthe practice of the invention, applied according to the practice of theinvention.

The invention is not limited to polyester yarn from any particularsource, and is specifically not limited to MD-21 yarn, or yarn made byany particular manufacturer. Instead, the invention is defined in partby the discovery of the chemical properties of any polyester yarn thatwill make such yarn suitable for airbag usage, as further set forthherein. Thus, a new manner of characterizing yarn for airbag use hasbeen achieved, and identified.

Table 1 below compares basic information of various polyester yarn typesdiscussed herein, for purposes of comparison. TABLE 1 Comparison ofProperties of Polyester Yarn Types PET 1 PET 2 MD-21 Manufacturer KOSAHoneywell Hyosung Yarn ID Type 781 Type 1W72 Type 560 Denier 650 540 500No. of filaments 140 140 96 Tenacity (g/d) 8.5 8.5 7.4 Elongation atBreak (%) 16 17 24.5

Surprisingly beneficial CEG values and IV values and ranges, which existafter aging, have not been discovered for use in airbag applicationsuntil the invention of this application.

Measurements on the IV and CEG levels in the polyester yarn of theinvention (MD-21 polyester yarn, as further described herein, as oneexample) were made on aged samples, and then compared to the controlsamples.

FIGS. 4-6 contain data from this work that represents the performance ofone of the polyester yarns that can be employed in use of MD-21 yarn.

Airbags were made from this new fabric formed from MD-21 yarn and theperformance of the fabric in the bag were evaluated. A burst pressure of22 Psi was achieved on control airbags and 20.7 psi on the aged fabricof the invention after 3000 hrs at 85° C. & 95% RH.

In addition to modifications in properties of the starting polymer,hydrolytic resistance can be improved by adding inhibitors to the basicpolymer before spinning the yarn so that polymer chain scission isminimized. Adding chemical inhibitors to improve hydrolytic resistanceof PET such that CEG levels below about 60 equivalents/10⁶ gram afteraging for 3000 hrs at 85° C. & 95% RH (relative humidity) can beemployed in the practice of the invention.

For purposes of this specification, heat and temperature aging exposureis provided according to the dictates of ASTM Standard D5427. That is,humidity aging as set forth in that specification is carried out in ahumidity chamber at about 80 degrees Centigrade and at about 95 percentrelative humidity (RH). The only significant deviation in the testingprovided herein from the ASTM Standard D5427 is the length of exposuretime. While the ASTM Standard D5427 calls for the specimens to remainundisturbed for 336 hours, for the current testing as set forth herein,exposure times may be longer. In the Figures, for example, exposuretimes of 1000, 2000, and 3000 hours are employed (See FIGS. 4-6) becausesuch long term exposures are demanded by some automotive manufacturers.Hence, these exposure times are more in accord with automotive industryrequirements.

It is also common in the airbag industry to reference the DelphiAutomotive Standards for Silicone Coated Cushion Material for Use inAirbag Cushions, which also references ASTM D5427.

In the practice of the invention, it is possible to calculate the esterbonds that have broken from the main polymer backbone as a function ofaging hours of exposure. The compositions of the invention showremarkable and unexpectedly superior aging properties over the prior artpolyester yarns, due in part to the resistance of this polyester toaging under the conditions encountered by airbags in automotive testing.

FIGS. 4 and 5 show performance of a yarn of the invention after theaging exposure. FIG. 4 shows a tensile strength after 3000 hours of suchexposure which is greater than about 400 lbs.

In the invention, it is believed that CEG values of less than 30, morepreferably less than 20 are desirable for the control yarn (initialpre-aged values). Furthermore, in the invention, it is believed that CEGvalues in aged yarn of less than about 60 equivalents/10⁶ grams may bedesirable after 3000 hours of exposure at 85° C. and 95% RH. Thus,essentially any polyester yarn having such characteristics is believedto be a candidate for application in this invention.

Furthermore, FIG. 5 shows a CEG level using one particular embodiment ofthe invention (i.e. MD-21 yarn) which shows, after 3000 hours exposure,less than about 30 equivalents/10⁶ grams, which is even moreadvantageous. Thus, the invention may employ levels of CEG below about60, and more preferably, below about 30 equivalents/10⁶ grams in CEGvalue after 1000 hours of exposure at 85° C. and 95% RH.

FIG. 6 shows a comparison of the total percentage of ester bonds brokenfor the prior art polyester compositions, over time, as compared to thetotal amount of ester bonds broken over time in one embodiment of theinvention. In FIG. 6, it can be seen that after 3000 hours, a number forpercentage of broken ester bonds below about 0.3, and more preferablybelow about 0.1, is possible in the practice of the invention.

The data in FIG. 6 reveal the calculated percentage of ester bonds thatare broken on the polymer structure at various points in time, which arecalculated as further set forth below.

Laboratory Procedure for Determining Total Acid Value (CEG)

The procedure for determining the total acid value, namely the CEG, isISO Standard 2114:2000 (E), Method B This International Standard is usedfor plastics and polyester resins for determining the partial acid value(Method A) and total acid value (Method B) of polyester resins andbinders. It is not applicable to phenolic resins.

In the practice of the invention, and for purposes of thisspecification, Method B was used. As provided in sections 8.2.1 and 4.3of this Standard, the amount in milligrams of KOH used to neutalize 1gram of resin was calculated. Then, the milligrams of KOH per gram wereconverted to micro-equivalents per gram of polymer, indicated asequivalents/10⁶ grams. The test results from this method was alsoverified in accordance with ASTM D664 and ASTM D4094 for CEGmeasurements.

Laboratory Procedure for Determining Instrinsic Viscosity (IV)

The time required for the specified volume of the polymer (solution) topass through the capillary tube of the viscometer was used to calculatethe intrinsic viscosity, according to laboratory procedures, asdescribed below.

First, a sample of about 0.1 grams of a given polyester fiber materialwas dissolved in a solution. The solution is a 60/40 mixture (by weight)of phenol and 1,1,2,3 tetra-chloroethane, to a concentration of 0.4gm/100 ml respectively.

The solution thus made as above is applied in a viscometer, such as forexample a Ubbelohde viscometer. The solution was poured into theviscometer and maintained at 30° C. on a water bath for at least 10minutes and the flow time of the solution was recorded as t₁.

Then, the solution above described (control) without the dissolved yarn(i.e., solvent) is measured in the same manner, upon the sameviscometer, under the same conditions. This measurement is t₂, andserves as a standard or control.

The Relative Viscosity (RV) then is determined, by dividing the time, t₁by time, t₂. The RV then is converted to Intrinsic viscosity, IV, by wayof the following equation:${{I.V} = {{\frac{1}{4}{\left( {{RV} - 1} \right)/C}} + {\frac{3}{4}l\quad{n\left( \frac{RV}{C} \right)}}}}\quad$Where, RV is the relative viscosity; IV is the intrinsic viscosity and Cis the concentration of the solution in gm/100 ml.

Determining % Broken Ester Bonds in the Backbone

Percent broken ester bonds (% BEB) is a ratio of the scission of esterbonds by hydrolysis to the total ester bonds on the control. Thisparameter was calculated from the I.V. measurements as described earlierwith the specific solvent used for the test as follows:% BEB=0.244└(I.V. _(final))⁻⁴¹⁷−(I.V. _(Control))^(−1.471)┘

Observations

From the above analysis it is clear that the polyester yarn degradationcan be monitored by changes in IV and CEG. For the first time, the workof this specification has enabled correlation between CEG, IV, and yarnperformance after aging, which is identified specifically for airbaguses.

Lower CEG levels in the control polymer/yarn lower the extent ofdegradation. The IV of the yarn advantageously may be about 0.6.Further, it has been found that CEG levels in the control polyester yarnwhich are below about 30, or more preferably below about 20equivalent/10⁶ grams, improve aging behavior.

Polyester yarns having an IV of at least about 0.6, or alternately atleast about 0.7, and also between about 0.5 and 0.8 are particularlyuseful. Furthermore, a polyester yarn exhibiting at least about 400 lbsof tensile strength after exposure to 3000 hours of temperature/humiditytesting is featured in a further aspect of the invention.

Polyester yarns having a CEG of less than about 30 equivalents/10⁶ gramshave been shown to be capable of passing automotive testingrequirements. It has been discovered that a CEG value of less than about30 equivalents/10⁶ grams correlates well with values of IV of between0.5 and 0.8, and such a polyester yarn is capable of superior agingcharacteristics.

It is understood by one of ordinary skill in the art that the presentdiscussion is a description of exemplary embodiments only, and is notintended as limiting the broader aspects of the present invention, whichbroader aspects are embodied in the exemplary constructions. Theinvention is shown by example in the appended claims.

1. An airbag comprised in part of woven polymeric polyester yarn, saidpolyester yarn exhibiting superior hydrolytic resistance, said yarnbeing capable of characterization by a carboxyl end group (CEG) value,wherein said yarn provides a CEG value of less than about 30equivalents/10⁶ grams after said yarn is exposed for at least about 336hours to a temperature of at least about 85 degrees Centigrade and arelative humidity of at least about 95 percent.
 2. The airbag of claim 1wherein said yarn further exhibits an IV value of at least about 0.6. 3.The airbag of claim 1 wherein said yarn further exhibits an IV value ofat least about 0.7.
 4. The airbag of claim 1 wherein said yarn furtherexhibits an IV value of between about 0.5 and about 0.8
 5. The airbag ofclaim 1 wherein said yarn provides a tensile strength of at least about400 lbs after said exposure.
 6. The airbag of claim 1 wherein thecalculated percentage of broken ester bonds in said yarn after saidexposure is less than about 0.3 percent.
 7. The airbag of claim 1wherein the calculated percentage of broken ester bonds in said yarnafter said exposure is less than about 0.1 percent.
 8. The airbag ofclaim 1 wherein said yarn further comprises chemical inhibitors or endgroup capping agents which serve to improve the overall hydrolyticresistance of said polyester yarn.
 9. A polymeric polyester yarn for usein airbags, said yarn exhibiting: (a) a CEG value of less than about 60equivalents/10⁶ grams after said yarn is exposed for at least about 3000hours to a temperature of at least about 85 degrees Centigrade and arelative humidity of at least about 95 percent, according to ASTM D5427as modified; and (b) an IV value of at least about 0.6.
 10. An airbagcushion, said airbag cushion comprising polyester yarn, said polyesteryarn having a CEG value—of less than about 60 equivalents/10⁶ gramsafter said yarn is exposed for at least about 3000 hours to atemperature of at least about 85 degrees Centigrade and a relativehumidity of at least about 95 percent.
 11. The airbag cushion of claim10 wherein said yarn further exhibits an IV value of at least about 0.6.12. The airbag cushion of claim 10 wherein said yarn further exhibits anIV value of at least about 0.7.
 13. The airbag cushion of claim 10wherein said yarn further exhibits an IV value of between about 0.5 andabout 0.8.
 14. The airbag cushion of claim 10 wherein said yarn providesa tensile strength of at least about 400 lbs when tested in accordancewith ASTM standard D5034 after said exposure.
 15. The airbag cushion ofclaim 10 wherein the calculated percentage of broken ester bonds in saidyarn after said exposure is less than about 0.3 percent.
 16. The airbagcushion of claim 10 wherein the calculated percentage of broken esterbonds in said yarn after said exposure is less than about 0.1 percent.17. The airbag cushion of claim 10 wherein said said polyester yarnfurther comprises chemical inhibitors or end group capping agents whichserve to improve the hydrolytic resistance of said polyester yarn. 18.An airbag comprised at least in part of woven polymeric polyester yarn,said polyester yarn exhibiting superior hydrolytic resistance, said yarnbeing capable of being characterized by a carboxyl end group value(CEG), said yarn further being capable of being characterized by anintrinsic viscosity (IV) value, wherein said yarn provides, after saidyarn is exposed for at least about 3000 hours to a temperature of atleast about 85 degrees Centigrade and a relative humidity of at leastabout 95 percent, the following: (a) an IV value of at least about 0.6;and (b) a CEG value of less than about 60 equivalents/10⁶ grams, and (c)a tensile strength of at least about 400 lbs.
 19. An airbag comprised inpart of woven polymeric polyester yarn, said polyester yarn exhibitingsuperior hydrolytic resistance, said yarn being capable of beingcharacterized by a carboxyl end group (CEG) value, wherein said yarnprovides a CEG value of less than about 30 equivalents/10⁶ grams aftersaid yarn is exposed for at least about 336 hours to a temperature of atleast about 85 degrees Centigrade and a relative humidity of at leastabout 95 percent, and further wherein said aged yarn after said exposureprovides a tensile strength of at least about 400 lbs.
 20. An airbagcushion comprising: at least one fabric portion including polyesteryarn, said polyester yarn exhibiting a CEG value of less than 30equivalents/10⁶ grams and IV value greater than 0.6.
 21. The airbagcushion of claim 20 wherein the tensile strength of said fabric portionis greater than about 275 lbs after exposure.
 22. The airbag of claim 20wherein the tensile strength of said fabric portion is greater thanabout 400 lbs after exposure.
 23. A woven airbag comprising polyesteryarn, said polyester yarn exhibiting a CEG value of less than about 30equivalents/10⁶ grams and an IV value greater than about 0.6.
 24. Theairbag of claim 23 wherein said CEG value is less than about 50equivalents/10⁶ grams after exposure to at least about 3000 hours at atemperature of at least about 85 degrees Centigrade and a relativehumidity of at least about 95 percent.
 25. The airbag of claim 23wherein said CEG value is less than about 40 after exposure to at leastabout 3000 hours at a temperature of at least about 85 degreesCentigrade and a relative humidity of at least about 95 percent.
 26. Anairbag comprised of polyester yarn, said polyester yarn retaining atleast about 85% of the tensile strength of said yarn after said yarn isexposed for at least 1000 hours at a temperature of at least about 85degrees Centigrade and a relative humidity of at least about 95 percent.27. An airbag comprised of polyester yarn, said polyester yarn retainingat least about 85% of the tensile strength of said yarn after said yarnis exposed to at least about 3000 hours at temperature of at least about85 degrees Centigrade and a relative humidity of at least about 95percent.